boot SSANGYONG KORANDO 1997 Service User Guide
[x] Cancel search | Manufacturer: SSANGYONG, Model Year: 1997, Model line: KORANDO, Model: SSANGYONG KORANDO 1997Pages: 2053, PDF Size: 88.33 MB
Page 1317 of 2053

MANUAL TRANSMISSION 5B-9
SSANGYONG MY2002
SEMI-REMOTE KIT DISASSEMBLY AND ASSEMBLY
YAD5B110
1 Remote Shift
2 Shift Lever
3 Shift Inner Boot
4 Lining Shift Socket
5 Control Housing Arm Insulator
6 Control Housing Arm
7 Bushing
8 Shift Rod Link
9 Washer
10 Clip
11 Shift Rod Pin
12 Cover Assembly
13 Shift Tower Cover14 Bolt
15 Breather Hose Bar
16 Control Shift Spring
17 Offset Control Lever
18 Retainer Ring
19 Pin
20 Shift Rail
21 Grove Pin
22 Pin & Clip
23 Joint Assembly
24 Joint Housing
25 Bushing
Page 1320 of 2053

SSANGYONG MY2002
5B-12 MANUAL TRANSMISSION
1 Remote Shift
2 Shift Lever
3 Shift Inner Boot
4 Lining Shift Socket
5 Control Housing Arm Insulator
6 Control Housing Arm
7 Bushing
8 Shift Rod Link
9 Washer
10 Clip
11 Shift Rod Pin
12 Cover Assembly
13 Shift Tower Cover
14 Bolt
15 Bleeder Hose Barb
16 Control Shift Spring
17 Offset Control Lever
18 Retainer Ring
19 Pin
20 Shift Rail
21 Groove Pin
22 Pin and Clip
23 Joint Assembly
24 Joint Housing
25 Bushing
26 Bolt
27 Bolt
28 O-ring
29 Shaft Rail
30 Case Cover
31 Cap Plug
32 Insert
33 Selecter Plate
34 Selecter Arm
35 Inlockter Plate
36 Selecter Arm Pin
37 Selecter Plate
38 Insert
39 Shift Fork
40 Output Shaft
41 Retainer Ring
42 Washer
43 Inner Corn
44 Outer-Race
45 1-2nd Blocking-Ring
46 Output Shaft Assembly
47 Insert
48 Ball
49 Spring
50 Reverse Sliding Gear
51 1-2nd Blocking-Ring
52 Outer Corn Race
53 Inner Corn
54 Sleeve Bearing
55 Sleeve
56 Needle Bearing
57 1st Speed Driven Gear58 Bearing Corn
59 Bearing Cup
60 Thrust Bearing
61 Thrust Race
62 Blocking-Ring
63 Spring
64 Insert
65 Synchronizer Sleeve
66 Spring
67 Blocking-Ring
68 Synchronizer
69 3rd Speed Gear
70 Needle Bearing
71 Spacer
72 Snap Ring
73 Washer
74 2nd Speed Gear
75 Needle Bearing
76 Spacer
77 Synchronizer Sleeve
78 Bearing
79 O-Ring
80 Bearing
81 Corn Bearing
82 Shaft Gear
83 Counter Shaft Gear
84 Corn Bearing
85 Roll Pin
86 Shift 5th Fork
87 Insert
88 Shift Rail
89 Reverse Fork
90 Spring
91 Retainer Ring
92 Shift Lever
93 5th Speed Driven Gear
94 Snap Ring
95 Bearing Cap
96 Shim
97 Rear Retainer
98 Bolt
99 5th Speed Driven Gear
100 Blocking 5th-Ring
101 Hub Bearing
102 Insert
103 Sleeve
104 Spring
105 Spring
106 Synchronizer
107 5th Synchronizer Retainer
108 Snap Ring
109 Oil Ring Funnel
110 Roll Pin
111 Reverse Idler Shaft
112 Reverse Idler Gear
113 O-Ring
114 Cross member Mounting Hole
Page 1359 of 2053

CLUTCH 5C-3
SSANGYONG MY2002
1 Clutch Disc
2 Clutch Cover
3 Clutch Housing
4 Release Bearing
5 Release Fork Pivot
6 Release Cylinder
7 Release Fork Boot
COMPONENT LOCATOR
CLUTCH ASSEMBLY
8 Bolt
9 Release Fork
10 Bolt
11 Spring Lock Washer
12 Transmission Input Spline
13 Release Bearing Contacting Surface
14 Contacting Point of Release Fork and Pivot
KAA5C010
Notice: Apply the long-term grease (DBL 6811.00) to No.12,13 and 14.
Page 1365 of 2053

SSAMGYONG MY2002
5C-10 CLUTCH
1 Snap Pin
2 Clevis Pin
3 Clevis
4 Lock Nut
5 Flange Nut.................... 8 - 18 Nm (6 - 13 lb-ft)
6 Push Rod
7 Cylinder Body
8 Oil Pipe..................... 15 - 18 Nm (11 - 13 lb-ft)
MASTER CYLINDER
9 Clamp
10 Reservoir
11 Spring
12 Piston Assembly
13 Boot
14 Plate
15 Snap Ring
KAA5C130
Notice: Do not disassemble the No. 12.
Page 1469 of 2053

SECTION 6C
POWER STEERING GEAR
TABLE OF CONTENTS
Description and Operation...................................6C-2
Power Rack and Pinion........................................6C-2
Component Locator.............................................6C-3
Diagnostic Information and Procedures..............6C-4
Power Steering Rack and Pinion Gear...................6C-4
Power Steering Rack and Pinion Gear Bench
Testing.............................................................6C-6
Straight-Ahead Check ..........................................6C-6
Repair Instructions................................................6C-8
On-Vehicle Service.................................................6C-8
Rack and Pinion Assembly..................................6C-8
Outer Tie Rod......................................................6C-9Dust Boot.......................................................... 6C-10
Intermediate Shaft............................................. 6C-10
Hydraulic Cylinder Lines.................................... 6C-11
Unit Repair.......................................................... 6C-13
Rack and Pinion................................................ 6C-13
Valve and Pinion Assembly................................ 6C-14
Rack Bearing.................................................... 6C-15
Rack Bearing Preload Adjustment...................... 6C-16
Specifications..................................................... 6C-17
Fastener Tightening Specifications..................... 6C-17
Special Tools and Equipment............................ 6C-18
Special Tools Table............................................ 6C-18
Page 1471 of 2053

POWER STEERING GEAR 6C-3
SSANGYONG MY2002
COMPONENT LOCATOR
KAA6C010
1 Intermediate Shaft
2 Lower Pinch Bolt
3 Boot
4 Outer Tie Rod
5 Return Line Pipe6 Rack and Pinion Assembly
7 Rack and Pinion Assembly Mounting Bolt
8 Castle Nut
9 Cotter Pin
10 Pressure Line Pipe
Page 1478 of 2053

SSANGYONG MY2002
6C-10 POWER STEERING GEAR
KAA6C090
KAA6C100
KAA6C110
KAA6C080
4. Loosen the outer tie rod adjusting nut and remove
the outer tie rod by twisting it off the inner tie rod.
Installation Notice:
After Installation, perform a front toe adjustment.
Refer to Section 2B, Wheel Alignment.
DUST BOOT
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to Section 2E, Tires and
wheels.
3. Remove the outer tie rod. Refer to “Outer Tie Rod”
in this section.
4. Remove the dust boot retaining clamps.
5. Remove the dust boot.
Installation Notice:
After Installation, perform a front toe adjustment.
Refer to Section 2B, Wheel Alignment.
INTERMEDIATE SHAFT
Removal and Installation Procedure
1. Turn the steering wheel until it is horizontal. This
is the straight-ahead position. Make a mark on
the stub shaft housing that lines up with a mark
on the intermediate shaft lower universal joint.
Installation Notice:
When attaching the lower universal joint, the
marks on the intermediate shaft and on the stub
shaft should line up
Page 1481 of 2053

POWER STEERING GEAR 6C-13
SSANGYONG MY2002
KAA6C150
UNIT REPAIR
RACK AND PINION
Disassembly and Assembly Procedure
1. Remove the rack and pinion assembly from the
vehicle. Refer to “Rack and Pinion Assembly” in
this section.
2. Remove the valve and pinion assembly from the
rack and pinion steering assembly. Refer to “Valve
and Pinion” in this section.
3. Remove the rack bearing assembly from the rack
and pinion steering assembly. Refer to “Rack
Bearing” in this section.
4. Mark the threads on the inner tie rod to aid in
repositioning the adjusting nut.
5. Loosen the adjusting nut and remove the outer tie
rod nut and the adjusting nut.
Installation Notice:
When installing the outer tie rod nut, the mark
on the inner tie rod and adjusting nut should
line up.
After installation, perform a front toe adjustment.
Refer to Section 2B, Wheel Alignment.
KAA6C160
KAA6C170
6. Remove the dust boot retaining clamps and
remove the dust boot.
7. Push back the retainer holding the connection be-
tween the inner tie rod and the power steering gear
rack.
Page 1752 of 2053

INTERIOR TRIM 9G-3
SSANGYONG MY2002
COMPONENTS LOCATOR
INTERIOR TRIM
1 Console Box
2 Tray
3 Arm Rest
4 Parking Lever Strip
5 Facia (BTRA A/T)
6 Indicator Cover7 Facia (M/T)
8 Boot Assembly (M/T)
9 Facia (MB A/T)
10 Rear Facia Strip
11 Rear Facia Cap
KAA9G010
Page 1781 of 2053

SQUEAKS AND RATTLES 9K-3
SSANGYONG MY2002
Check for a lack of lubrication of the door hinge pins.ChecksActionOperate the doors and listen for squeaks.
Lubricate the door hinge pins with light oil and coat
with lithium grease.
Squeak Coming From Console When Shifting Manual Transaxle
(Condition Occurs In Cold Weather with a Cold Engine)
Check the manual transaxle control lever lower boot.ChecksActionMove the control lever between gears and listen for
squeaks.
Remove the floor console and replace the lower shift
boot or apply talcum powder to the lower shift boot.
Squeak When Operating Doors
Check for vibration of the fuse box cover against the
instrument panel side trim.ChecksActionTap on thecoverwith a fingerandlisten fora buzz.
Apply 6.35 mm (0.250 inch) by 25.4 mm (1.00 inch)
felt pads to the side trim where the cover makes
contact.
Squeak Coming From Instrument Cluster Trim Plate
Check for rubbing of the cluster trim plate on the
instrument panel.ChecksActionTest drive the vehicle in order to verify this condi-
tion.
Remove the instrument cluster trim plate and install
felt tape to the edges.
Buzz From the Left Side of Instrument Panel
Check the door lock solenoid.
Check for rattling electrical connectors inside the door
trim panel.ChecksActionRemove the door trim panel and check if the sole-
noid is loose.
Tighten the solenoid bolts.
Tap on the trim panel and listen for a rattle.
Remove the trim panel and wrap foam padding
around the connectors as required.
Rattle Coming From Door